US4112021A - Process for producing thermoplastic resin - Google Patents
Process for producing thermoplastic resin Download PDFInfo
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- US4112021A US4112021A US05/750,766 US75076676A US4112021A US 4112021 A US4112021 A US 4112021A US 75076676 A US75076676 A US 75076676A US 4112021 A US4112021 A US 4112021A
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F279/00—Macromolecular compounds obtained by polymerising monomers on to polymers of monomers having two or more carbon-to-carbon double bonds as defined in group C08F36/00
- C08F279/02—Macromolecular compounds obtained by polymerising monomers on to polymers of monomers having two or more carbon-to-carbon double bonds as defined in group C08F36/00 on to polymers of conjugated dienes
- C08F279/04—Vinyl aromatic monomers and nitriles as the only monomers
Definitions
- the present invention relates to a process for producing a thermoplastic resin having excellent impact resistance and processability. More particularly, it relates to a process for producing a thermoplastic resin by polymerizing an aromatic monovinyl monomer and a vinyl cyanide monomer in the presence of an aqueous elastomeric latex, mixing with agitation the resulting copolymer latex with an aromatic monovinyl monomer and a vinyl cyanide monomer in the presence of a polyalkylene oxide and a coagulant and polymerizing the mixture, and the thermoplastic resin thus produced, and a composition comprises said thermoplastic resin and a copolymer produced from an aromatic monovinyl monomer and a vinyl cyanide monomer.
- thermoplastic resins having an impact resistance by the suspension polymerization of a mixture of an elastomeric latex and polymerizable monomers have, hitherto, been proposed various processes for producing thermoplastic resins having an impact resistance by the suspension polymerization of a mixture of an elastomeric latex and polymerizable monomers.
- the polymerization is carried out by admixing both a water-soluble polymerization initiator and an oil-soluble polymerization initiator to a mixture of an elastomeric latex and monomers, wherein a suspending agent (e.g. polyvinyl alcohol) is previously present in the polymerization system, and thereby the polymerization system is changed from the state of emulsion to suspension during the polymerization reaction and then the polymerization reaction is completed (cf Japanese Patent Publication No. 21073/1968).
- a suspending agent e.g. polyvinyl alcohol
- this process has some defects that when the phase transition from the emulsion to the suspension of the polymerization system is accompanied with undesirable increase of the viscosity, blocking and coagulation of the system and further the fouling of the polymer onto the polymerization vessel. Moreover, this process is hardly applied to the production of the polymer having excellent properties like ABS resin (acrylonitrile-butadiene-styrene resin) which is the representative polymer produced by the present invention. Besides, when the desired polymer is produced by this known process, the reaction conditions must be severely controlled, for which a highly skilled person is required.
- An object of the present invention is to provide an improved process for producing a thermoplastic resin having excellent impact resistance and processability.
- Another object of the invention is to provide a process for producing the desired thermoplastic resin simply and safely.
- a further object of the invention is to provide the thermoplastic resin thus produced.
- a still further object of the invention is to provide a thermoplastic resin composition.
- the desired thermoplastic resin can be produced by previously polymerizing an aromatic monovinyl monomer and a vinyl cyanide monomer in the presence of an aqueous elastomeric latex, mixing with agitation the resulting copolymer latex with an aromatic monovinyl monomer and a vinyl cyanide monomer in the presence of a polyalkylene oxide and a coagulant to give a stable suspension phase, and graft-polymerizing with agitation the mixture, and the desired thermoplastic resin composition can be produced by mixing the thermoplastic resin obtained above with a copolymer produced from an aromatic monovinyl monomer and a vinyl cyanide monomer.
- thermoplastic resin obtained by the present invention has the following excellent properties.
- Stabilizers, lubricants, pigments or the like can easily and tightly be adhered onto the granules of the resin and a Henschel mixer, etc. Accordingly, there is no problem, such as separation or peeling of additives, during the transportation thereof by an air pressure or a screw.
- composition of the present thermoplastic resin with another copolymer has far higher impact strength in comparison with the composition of the conventional thermoplastic resin with another copolymer.
- the amount of the polyalkylene oxide is so small, and therefore, the waste liquid has a far lower concentration and can be more easily treated, in comparison with the waste liquid produced in the conventional polymerization reaction using a suspending agent, and
- the polymerization system has a lower viscosity, and therefore, the polymerization conditions, such as polymerization temperature, can very easily be controlled.
- the elastomeric latex used in the present invention includes a butadiene latex (e.g. polybutadiene latex, butadiene-styrene copolymer latex, butadiene-acrylonitrile copolymer latex), an elastomeric latex of chloroprene and acrylic esters, or the like.
- a butadiene latex e.g. polybutadiene latex, butadiene-styrene copolymer latex, butadiene-acrylonitrile copolymer latex
- an elastomeric latex of chloroprene and acrylic esters or the like.
- the monomers to be polymerized in the presence of the elastomeric latex include aromatic monovinyl monomers [e.g. styrene, ⁇ -methylstyrene, vinyltoluene, monochlorostyrene, etc.] and vinyl cyanide monomers (e.g. acrylonitrile, methacrylonitrile, etc.). These monomers may be used alone or in a combination thereof.
- aromatic monovinyl monomers e.g. styrene, ⁇ -methylstyrene, vinyltoluene, monochlorostyrene, etc.
- vinyl cyanide monomers e.g. acrylonitrile, methacrylonitrile, etc.
- the ratio of the monomers to be polymerized in the presence of the elastomeric latex is not critical, but it is usually preferable to use in the ratio of 10 to 200 parts by weight, more preferably 20 to 100 parts by weight, of the monomers per 100 parts by weight of the elastomer contained in the elastomeric latex (i.e. the solid components in the latex) from the economical viewpoint.
- the ratio of each monomer is not critical, either, but it is usually used in the ratio of 20 to 40% by weight of the vinyl cyanide monomer per 80 to 60% by weight of the aromatic monovinyl monomer, from the viewpoint of the desirably balanced properties of the final composition.
- the polymerization of the aromatic monovinyl monomer and the vinyl cyanide monomer in the presence of the elastomeric latex can be carried out under the same conditions as in the conventional emulsion polymerization reaction.
- the ratio of the monomers to be subsequently polymerized with the copolymer latex is not critical, either, but it is usually preferable to use in the ratio of 30 to 2000 parts by weight, more preferably 100 to 1000 parts by weight, of the monomers per 100 parts by weight of the elastomer contained in the copolymer latex.
- the monomers i.e. the aromatic monovinyl monomer and the vinyl cyanide monomer, are the same or different from those used in the foregoing polymerization and include the monomers as mentioned above.
- the ratio of the monomers to the elastomer in the final thermoplastic resin is not critical, but it is preferable that the content of the elastomer is 5 to 70% by weight and the content of the monomers is 95 to 30% by weight.
- the elastomer is contained in an amount of less than 5% by weight, the thermoplastic resin is inferior in the impact strength.
- the addition of the monomers to the polymerization system may be carried out in the same manner as in the conventional graft polymerization reaction.
- the polyalkylene oxide used in the present invention includes a polymer of an alkylene oxide having 2 to 3 carbon atoms, such as polyethylene oxide or polypropylene oxide.
- the molecular weight of the polyalkylene oxide ranges from 2 ⁇ 10 4 to 1 ⁇ 10 7 , preferably from 1 ⁇ 10 6 to 5 ⁇ 10 6 .
- the molecular weight of the polyalkylene oxide is smaller than the above range, it must be used in a larger amount for the polymerization reaction, and on the other hand, when the molecular weight is too large, the aqueous solution thereof is gelled and therefore is hardly handled.
- the polyalkylene oxide is used in an amount of 0.001 to 0.5 part by weight, preferably 0.01 to 0.3 part by weight, per 100 parts by weight of total weight of the copolymer latex (solid components) and the monomers.
- the polyalkylene oxide is used in an amount of less than 0.001 part by weight, the mixture does not become a stable dispersion phase, and on the other hand, when the amount is over 0.5 part by weight, it induces trouble in the treatment of the waste liquid and further deteriorates the heat stability and mechanical properties of the final resin product.
- a polymerization initiator such as a water-soluble polymerization initiator and an oil-soluble polymerization initiator, which may be used alone or in a combination thereof.
- Suitable examples of the polymerization initiator are lauroyl peroxide, t-butyl peroxypivalate, benzoyl peroxide, or the like, in order to enhance the degree of grafting.
- a chain transfer agent such as t-dodecylmercaptan or n-dodecylmercaptan, and an antioxidant, such as trisnonylphenyl phosphite, may also optionally be used in the polymerization reaction.
- the coagulant used in the present invention includes acids and water-soluble inorganic salts, which are usually used for coagulating the conventional emulsion polymerization products.
- Suitable examples of the acids are an inorganic acid having a dissociation constant of 1 ⁇ 10 -5 or more at 25° C, such as hydrochloric acid, sulfuric acid or nitric acid, and an organic acid having 1 to 10 carbon atoms and having a dissociation constant of 1 ⁇ 10 -5 or more at 25° C, such as formic acid, acetic acid, oxalic acid or n-butyrice acid.
- the water-soluble inorganic salts include a salt of an acid (e.g.
- a metal such as monovalent, divalent or trivalent metal (e.g. sodium, potassium, magnesium, calcium, barium, aluminum, iron, etc.).
- the number of ionic charge of the metal is not critical, but the amount of the salt varies with the number of ionic charge.
- Suitable examples of the water-soluble inorganic salt are sodium sulfate and magnesium sulfate.
- the suitable kind and amount of the coagulant may be optionally elected from the standpoint of the mechanical stability of the aqueous elastomeric latex used.
- the amount of the coagulant may vary with the kind of the coagulant, but is usually in the range of 0.01 to 20 parts by weight per 100 parts by weight of total weight of the copolymer latex (solid components) and the monomers.
- the polymerization of the present invention is carried out without using the coagulant, i.e. only by using the polyalkylene oxide alone, the polymerization reaction is remarkedly unstable, and therefore, the polyalkylene oxide should be used in a larger amount, such as several to ten several times of the amount in case of using a coagulant, and furthermore, there are not improved the defects as in the conventional process, such as the production of micro-particles or turbidness of the filtrate of the reaction product.
- the coagulant and the polyalkylene oxide are used together, such defects are eliminated.
- the copolymer to be mixed with the thermoplastic resin obtained by the process of the present invention is a copolymer produced from an aromatic monovinyl monomer and a vinyl cyanide monomer. Suitable examples of these monomers are the same as described hereinbefore.
- the ratio of the monomers for the copolymer is not critical, but they are preferably used in the ratio of 20 to 40% by weight of the vinyl cyanide monomer per 80 to 60% by weight of the aromatic monovinyl monomer.
- the copolymer may be produced by a conventional polymerization processes, such as an emulsion polymerization, suspension polymerization, solution polymerization, or the like.
- the copolymer may be admixed with the thermoplastic resin in the ratio of 95% by weight or lower, preferably not more than 90% by weight, on the basis of the whole weight of the mixture.
- the copolymer is admixed over 95% by weight, the final composition has a lower Izod impact strength.
- the present invention is illustrated by the following Examples, but is not limited thereto.
- polybutadiene 70 parts by weight, as solid material
- styrene 21 parts by weight
- acrylonitrile 9 parts by weight
- the resulting copolymer latex (1,800 g, the solid materials: 41%) is mixed with deionized water (3,200 g) and the mixture is agitated at 300 r.p.m.
- a mixture of styrene (896 g), acrylonitrile (384 g), lauroyl peroxide (3.2 g), t-dodecylmercaptan (10 g) and tris-nonylphenyl phosphite (10 g) and thereto are further added a 1% aqueous solution of polyethylene oxide having an average molecular weight of 2 ⁇ 10 6 (100 g) and a 5% aqueous solution of sodium sulfate (1,600 g).
- the mixture is heated up to 70° C and polymerized for 5 hours.
- the agitation can be done with the power which is usually used in the conventional emulsion polymerization.
- the polymerization system has a further lower viscosity, and the resulting polymer dispersion can very easily be handled.
- reaction product After the polymerization reaction, the reaction product is cooled, filtered, washed with water, and then dried at 70° C for 5 hours.
- the granular particles thus obtained have a narrow distribution of particle sizes as shown below and are white, bulky and homogeneous particles.
- the granular particles (100 parts by weight) are admixed with calcium stearate (0.3 part by weight) and Sumilizer® BHT (an antioxidant, made by Sumitomo Chemical Company, Limited, 0.3 part by weight). After mixing well, the mixture is moled by an injection molding to give a test piece. As the result, the granular particles are well bitten into the injection machine with good rate of injection molding.
- Sumilizer® BHT an antioxidant, made by Sumitomo Chemical Company, Limited
- Example 1 is repeated except that a 5% aqueous solution of sodium sulfate (500 g) and a 0.5% aqueous solution of magnesium sulfate (50 g) are used instead of the 5% aqueous solution of sodium sulfate (1,600 g) and the deionized water is used in an amount of 4,270 g instead of 3,200 g.
- the granular particles thus obtained have the following distribution of particle sizes:
- the granular particles can be molded by an injection molding without any trouble as like as in Example 1.
- the polymerization is carried out except that the 1% aqueous solution of polyethylene oxide is used in an amount of 60 g instead of 100 g, and the deionized water is used in an amount of 4,300 g.
- the granular particles thus obtained have the following distribution of particle sizes:
- the granular particles can be molded by an injection molding without any trouble as like as in Example 1.
- polybutadiene latex 70 parts by weight
- styrene 21 parts by weight
- acrylonitrile 9 parts by weight
- the polymer latex thus obtained (1,800 g, the solid materials: 41%) is mixed with deionized water (3,055 g), and the mixture is agitated at 600 r.p.m.
- the beads-like particles thus obtained have the following distribution of particle sizes and are faint yellow and semi-transparent.
- the filtrate obtained above is white and unclear, and there are a large amount of adhesion of the polymer onto the reactor wall and the agitating blades.
- the agitation should be done with a large power, and about two times or more of agitation rate than that in the present invention is required in order to effect the homogeneous mixing.
- the molded product obtained therefrom shows undesirable silver streaks and can not be practically used.
- the beads-like particles (100 parts by weight) are admixed with calcium stearate (0.3 part by weight) and Sumilizer® BHT (0.3 part by weight). After mixing well, the mixture is directly molded by an injection molding. As the result, the beads-like particles are badly bitten into the injection machine and therefore it is necessary to slow the rate of the injection molding.
- polybutadiene latex 70 parts by weight
- styrene 21 parts by weight
- acrylonitrile 9 parts by weight
- the graft polymer thus obtained (1,800 g, the solid materials: 41%) is mixed with deionized water (4,144 g), and the mixture is agitated at 300 r.p.m.
- styrene 896 g
- acrylonitrile 384 g
- lauroyl peroxide 3.2 g
- t-dodecylmercaptan 10 g
- tris-monylphenyl phosphite 10 g
- the mixture is heated up to 75° C and polymerized for 5 hours. After the polymerization reaction, the reaction product is cooled, filtered, washed with water and dried at 70° C for 13 hours. The filtrate thus obtained is white and unclear.
- the agitation power is higher than that in Examples 1 to 3 of the present invention, but it is not necessary to increase the rate of the agitation as in Reference Example 1.
- the time for drying of the particles obtained in this Reference Example 2 is shorter than that in Reference Example 1, but is far longer than that in Example 1 to 3.
- the particles of Reference Example 2 has the following distribution of particle sizes:
- the particles (100 parts by weight) are admixed with calcium stearate (0.3 part by weight) and Sumilizer® BHT (0.3 part by weight). After mixing well, the mixture is directly molded by an injection molding. As the result, the particles are badly bited into the injection machine as like as in Reference Example 1.
- Example 1 to 3 Various properties of the products in Example 1 to 3 and in Reference Example 1 and 2 were measured on the molded test pieces. The results are shown in the following Table 1.
- the polymer obtained in Reference Example 1 is mixed with styrene-acrylonitrile copolymer used in Example 4 together with an additive in the ratio as mentioned in the following Table 2.
- the mixture is directly molded by an injection molding to give test pieces.
- Example 4 Various properties of the test samples in Example 4 and Reference Example 3 were measured. The results are shown in Table 2.
- the polymer obtained in Reference Example 2 is mixed with styrene-acrylonitrile copolymer as used in Example 5 together with an additive in the ratio as mentioned in the following Table 3.
- the mixture is directly molded by an injection molding to give test pieces.
- Example 5 Various properties of the molded products in Example 5 and Reference Example 4 were measured. The results are shown in Table 3.
Abstract
A process for producing a thermoplastic resin having excellent impact resistance and processability, which comprises polymerizing an aromatic monovinyl monomer and a vinyl cyanide monomer in the presence of an aqueous elastomeric latex, mixing with agitation the resulting copolymer latex with an aromatic monovinyl monomer and a vinyl cyanide monomer in the presence of a polyalkylene oxide and a coagulant to give a stable suspension phase, and polymerizing the mixture, and said thermoplastic resin thus produced, and a composition comprising said thermoplastic resin and a copolymer produced from an aromatic monovinyl monomer and a vinyl cyanide monomer.
Description
The present invention relates to a process for producing a thermoplastic resin having excellent impact resistance and processability. More particularly, it relates to a process for producing a thermoplastic resin by polymerizing an aromatic monovinyl monomer and a vinyl cyanide monomer in the presence of an aqueous elastomeric latex, mixing with agitation the resulting copolymer latex with an aromatic monovinyl monomer and a vinyl cyanide monomer in the presence of a polyalkylene oxide and a coagulant and polymerizing the mixture, and the thermoplastic resin thus produced, and a composition comprises said thermoplastic resin and a copolymer produced from an aromatic monovinyl monomer and a vinyl cyanide monomer.
There have, hitherto, been proposed various processes for producing thermoplastic resins having an impact resistance by the suspension polymerization of a mixture of an elastomeric latex and polymerizable monomers.
For instance, (A) the polymerization is carried out by admixing both a water-soluble polymerization initiator and an oil-soluble polymerization initiator to a mixture of an elastomeric latex and monomers, wherein a suspending agent (e.g. polyvinyl alcohol) is previously present in the polymerization system, and thereby the polymerization system is changed from the state of emulsion to suspension during the polymerization reaction and then the polymerization reaction is completed (cf Japanese Patent Publication No. 21073/1968).
However, this process has some defects that when the phase transition from the emulsion to the suspension of the polymerization system is accompanied with undesirable increase of the viscosity, blocking and coagulation of the system and further the fouling of the polymer onto the polymerization vessel. Moreover, this process is hardly applied to the production of the polymer having excellent properties like ABS resin (acrylonitrile-butadiene-styrene resin) which is the representative polymer produced by the present invention. Besides, when the desired polymer is produced by this known process, the reaction conditions must be severely controlled, for which a highly skilled person is required.
(B) For preventing the fouling of the polymer onto the polymerization vessel as in the above process, there has been proposed an improved process wherein an aqueous solution of an electrolyte is added to the polymerization system while the phase transition from the emulsion to the suspension occurs (cf Japanese Patent Publication No. 84893/1973).
(C) There has also been proposed a process for the suspension polymerization of a mixture of an elastomeric latex or a graft latex thereof and monomers by using a suspending agent (e.g. polyvinyl alcohol), wherein a coagulant (e.g. an acid or an electrolyte) is added to the mixture of the latex and monomers with vigorous agitation (cf Japanese Patent Publication No. 25191/1974).
However, the above (B) and (C) processes require the vigorous agitation when the phase transition from the emulsion to the suspension occurs, and as the result, many bubbles are unfavorably produced in the polymerization system to give floating beads. Besides, when the polymer in the form of beads is accidentally scattered on the floor, it is very dangerous for walking around them and incidentally endangers people's lives within a laboratory or a factory.
As the results of the extensive studies, the present inventors have now found an improved process for producing the desired thermoplastic resins without such defects as in the conventional processes.
An object of the present invention is to provide an improved process for producing a thermoplastic resin having excellent impact resistance and processability.
Another object of the invention is to provide a process for producing the desired thermoplastic resin simply and safely.
A further object of the invention is to provide the thermoplastic resin thus produced.
A still further object of the invention is to provide a thermoplastic resin composition.
These and other objects of the invention will be apparent from the following description.
According to the present invention, the desired thermoplastic resin can be produced by previously polymerizing an aromatic monovinyl monomer and a vinyl cyanide monomer in the presence of an aqueous elastomeric latex, mixing with agitation the resulting copolymer latex with an aromatic monovinyl monomer and a vinyl cyanide monomer in the presence of a polyalkylene oxide and a coagulant to give a stable suspension phase, and graft-polymerizing with agitation the mixture, and the desired thermoplastic resin composition can be produced by mixing the thermoplastic resin obtained above with a copolymer produced from an aromatic monovinyl monomer and a vinyl cyanide monomer.
The thermoplastic resin obtained by the present invention has the following excellent properties.
(1) It has an excellent impact resistance and processability.
(2) It has an excellent tensile strength.
(3) It can rapidly be dried because it is in the form of granule.
(4) It is not dangerous even if it is scattered on the floor because of the granular form, contrary to the conventional thermoplastic resins which are in the form of beads.
(5) It can be molded by an injection molding without through the compounding step.
(6) Stabilizers, lubricants, pigments or the like can easily and tightly be adhered onto the granules of the resin and a Henschel mixer, etc. Accordingly, there is no problem, such as separation or peeling of additives, during the transportation thereof by an air pressure or a screw.
(7) The composition of the present thermoplastic resin with another copolymer has far higher impact strength in comparison with the composition of the conventional thermoplastic resin with another copolymer.
(8) The advantages in the process of the present invention are as follows:
(i) the agitation can be done with a lower power,
(ii) the floating beads are very few,
(iii) the amount of the polyalkylene oxide is so small, and therefore, the waste liquid has a far lower concentration and can be more easily treated, in comparison with the waste liquid produced in the conventional polymerization reaction using a suspending agent, and
(iv) the polymerization system has a lower viscosity, and therefore, the polymerization conditions, such as polymerization temperature, can very easily be controlled.
The elastomeric latex used in the present invention includes a butadiene latex (e.g. polybutadiene latex, butadiene-styrene copolymer latex, butadiene-acrylonitrile copolymer latex), an elastomeric latex of chloroprene and acrylic esters, or the like. These elastomeric latices may be used alone or in a combination of two or more thereof.
The monomers to be polymerized in the presence of the elastomeric latex include aromatic monovinyl monomers [e.g. styrene, α-methylstyrene, vinyltoluene, monochlorostyrene, etc.] and vinyl cyanide monomers (e.g. acrylonitrile, methacrylonitrile, etc.). These monomers may be used alone or in a combination thereof.
The ratio of the monomers to be polymerized in the presence of the elastomeric latex is not critical, but it is usually preferable to use in the ratio of 10 to 200 parts by weight, more preferably 20 to 100 parts by weight, of the monomers per 100 parts by weight of the elastomer contained in the elastomeric latex (i.e. the solid components in the latex) from the economical viewpoint. Besides, the ratio of each monomer is not critical, either, but it is usually used in the ratio of 20 to 40% by weight of the vinyl cyanide monomer per 80 to 60% by weight of the aromatic monovinyl monomer, from the viewpoint of the desirably balanced properties of the final composition.
The polymerization of the aromatic monovinyl monomer and the vinyl cyanide monomer in the presence of the elastomeric latex can be carried out under the same conditions as in the conventional emulsion polymerization reaction.
Furthermore, the ratio of the monomers to be subsequently polymerized with the copolymer latex is not critical, either, but it is usually preferable to use in the ratio of 30 to 2000 parts by weight, more preferably 100 to 1000 parts by weight, of the monomers per 100 parts by weight of the elastomer contained in the copolymer latex. The monomers, i.e. the aromatic monovinyl monomer and the vinyl cyanide monomer, are the same or different from those used in the foregoing polymerization and include the monomers as mentioned above. Thus, the ratio of the monomers to the elastomer in the final thermoplastic resin is not critical, but it is preferable that the content of the elastomer is 5 to 70% by weight and the content of the monomers is 95 to 30% by weight. When the elastomer is contained in an amount of less than 5% by weight, the thermoplastic resin is inferior in the impact strength.
The addition of the monomers to the polymerization system may be carried out in the same manner as in the conventional graft polymerization reaction.
The polyalkylene oxide used in the present invention includes a polymer of an alkylene oxide having 2 to 3 carbon atoms, such as polyethylene oxide or polypropylene oxide. The molecular weight of the polyalkylene oxide ranges from 2 × 104 to 1 × 107, preferably from 1 × 106 to 5 × 106. When the molecular weight of the polyalkylene oxide is smaller than the above range, it must be used in a larger amount for the polymerization reaction, and on the other hand, when the molecular weight is too large, the aqueous solution thereof is gelled and therefore is hardly handled. The polyalkylene oxide is used in an amount of 0.001 to 0.5 part by weight, preferably 0.01 to 0.3 part by weight, per 100 parts by weight of total weight of the copolymer latex (solid components) and the monomers. When the polyalkylene oxide is used in an amount of less than 0.001 part by weight, the mixture does not become a stable dispersion phase, and on the other hand, when the amount is over 0.5 part by weight, it induces trouble in the treatment of the waste liquid and further deteriorates the heat stability and mechanical properties of the final resin product.
In the polymerization of the present invention, there may also be used a polymerization initiator, such as a water-soluble polymerization initiator and an oil-soluble polymerization initiator, which may be used alone or in a combination thereof. Suitable examples of the polymerization initiator are lauroyl peroxide, t-butyl peroxypivalate, benzoyl peroxide, or the like, in order to enhance the degree of grafting.
A chain transfer agent, such as t-dodecylmercaptan or n-dodecylmercaptan, and an antioxidant, such as trisnonylphenyl phosphite, may also optionally be used in the polymerization reaction.
The coagulant used in the present invention includes acids and water-soluble inorganic salts, which are usually used for coagulating the conventional emulsion polymerization products. Suitable examples of the acids are an inorganic acid having a dissociation constant of 1 × 10-5 or more at 25° C, such as hydrochloric acid, sulfuric acid or nitric acid, and an organic acid having 1 to 10 carbon atoms and having a dissociation constant of 1 × 10-5 or more at 25° C, such as formic acid, acetic acid, oxalic acid or n-butyrice acid. The water-soluble inorganic salts include a salt of an acid (e.g. sulfuric acid, hydrochloric acid, acetic acid, etc.) with a metal, such as monovalent, divalent or trivalent metal (e.g. sodium, potassium, magnesium, calcium, barium, aluminum, iron, etc.). The number of ionic charge of the metal is not critical, but the amount of the salt varies with the number of ionic charge. Suitable examples of the water-soluble inorganic salt are sodium sulfate and magnesium sulfate. Besides, the suitable kind and amount of the coagulant may be optionally elected from the standpoint of the mechanical stability of the aqueous elastomeric latex used. The amount of the coagulant may vary with the kind of the coagulant, but is usually in the range of 0.01 to 20 parts by weight per 100 parts by weight of total weight of the copolymer latex (solid components) and the monomers.
When the polymerization of the present invention is carried out without using the coagulant, i.e. only by using the polyalkylene oxide alone, the polymerization reaction is remarkedly unstable, and therefore, the polyalkylene oxide should be used in a larger amount, such as several to ten several times of the amount in case of using a coagulant, and furthermore, there are not improved the defects as in the conventional process, such as the production of micro-particles or turbidness of the filtrate of the reaction product. When the coagulant and the polyalkylene oxide are used together, such defects are eliminated.
The copolymer to be mixed with the thermoplastic resin obtained by the process of the present invention is a copolymer produced from an aromatic monovinyl monomer and a vinyl cyanide monomer. Suitable examples of these monomers are the same as described hereinbefore. The ratio of the monomers for the copolymer is not critical, but they are preferably used in the ratio of 20 to 40% by weight of the vinyl cyanide monomer per 80 to 60% by weight of the aromatic monovinyl monomer.
The copolymer may be produced by a conventional polymerization processes, such as an emulsion polymerization, suspension polymerization, solution polymerization, or the like. The copolymer may be admixed with the thermoplastic resin in the ratio of 95% by weight or lower, preferably not more than 90% by weight, on the basis of the whole weight of the mixture. When the copolymer is admixed over 95% by weight, the final composition has a lower Izod impact strength.
The present invention is illustrated by the following Examples, but is not limited thereto.
By a usual emulsion polymerization process, polybutadiene (70 parts by weight, as solid material) is polymerized with styrene (21 parts by weight) and acrylonitrile (9 parts by weight) in a 10 liter glass reactor, wherein the air in the reactor is replaced with nitrogen gas.
After the polymerization, the resulting copolymer latex (1,800 g, the solid materials: 41%) is mixed with deionized water (3,200 g) and the mixture is agitated at 300 r.p.m. To the mixture is added at one time a mixture of styrene (896 g), acrylonitrile (384 g), lauroyl peroxide (3.2 g), t-dodecylmercaptan (10 g) and tris-nonylphenyl phosphite (10 g) and thereto are further added a 1% aqueous solution of polyethylene oxide having an average molecular weight of 2 × 106 (100 g) and a 5% aqueous solution of sodium sulfate (1,600 g). The mixture is heated up to 70° C and polymerized for 5 hours. During the polymerization reaction, the agitation can be done with the power which is usually used in the conventional emulsion polymerization. At the end of the reaction, the polymerization system has a further lower viscosity, and the resulting polymer dispersion can very easily be handled.
After the polymerization reaction, the reaction product is cooled, filtered, washed with water, and then dried at 70° C for 5 hours.
The granular particles thus obtained have a narrow distribution of particle sizes as shown below and are white, bulky and homogeneous particles. tris-nonylphenyl
Distribution of particle sizes:
______________________________________ Mesh 20 40 60 80 100 100 passed ______________________________________ % 8 65 25 2 0 0 ______________________________________
The filtrate obtained above is clear, and there is no adhesion of the polymer onto the reactor wall and the agitating blades.
The granular particles (100 parts by weight) are admixed with calcium stearate (0.3 part by weight) and Sumilizer® BHT (an antioxidant, made by Sumitomo Chemical Company, Limited, 0.3 part by weight). After mixing well, the mixture is moled by an injection molding to give a test piece. As the result, the granular particles are well bitten into the injection machine with good rate of injection molding.
The Example 1 is repeated except that a 5% aqueous solution of sodium sulfate (500 g) and a 0.5% aqueous solution of magnesium sulfate (50 g) are used instead of the 5% aqueous solution of sodium sulfate (1,600 g) and the deionized water is used in an amount of 4,270 g instead of 3,200 g.
The granular particles thus obtained have the following distribution of particle sizes:
______________________________________ Mesh 20 40 60 80 100 100 passed ______________________________________ % 5 70 23 2 0 0 ______________________________________
The granular particles can be molded by an injection molding without any trouble as like as in Example 1.
In the same manner as described in Example 2, the polymerization is carried out except that the 1% aqueous solution of polyethylene oxide is used in an amount of 60 g instead of 100 g, and the deionized water is used in an amount of 4,300 g.
The granular particles thus obtained have the following distribution of particle sizes:
______________________________________ Mesh 20 40 60 80 100 100 passed ______________________________________ % 8 60 27 5 0 0 ______________________________________
The granular particles can be molded by an injection molding without any trouble as like as in Example 1.
In the same manner as described in Example 1, polybutadiene latex (70 parts by weight), styrene (21 parts by weight) and acrylonitrile (9 parts by weight) are polymerized in a 10 liter glass reactor. The polymer latex thus obtained (1,800 g, the solid materials: 41%) is mixed with deionized water (3,055 g), and the mixture is agitated at 600 r.p.m. To the mixture are added a 5% aqueous solution of polyvinyl alcohol (made by Nippon Gosei Kagaku Kogyo K.K., 68.3 g) and a 3% aqueous solution of Metolose® (methyl cellulose derivative, made by Shin-Etsu Chemical Co., Ltd., 68.3 g) and thereto are further added styrene (896 g), acrylonitrile (384 g) and t-dodecylmercaptan (7.8 g). To the mixture is added dropwise a 5% aqueous solution of acetic acid (130 g) over a period of 15 minutes and thereto are further added a solution of magnesium sulfate (73.8 g) in water (390 g) and lauroyl peroxide (13.7 g). The mixture is agitated for 30 minutes and heated up to 75° C and then polymerized for 5 hours. After the polymerization reaction, the reaction mixture is cooled, filtered, washed with water and dried at 70° C for 35 hours.
The beads-like particles thus obtained have the following distribution of particle sizes and are faint yellow and semi-transparent.
Distribution of particle sizes:
______________________________________ Mesh 20 40 60 80 100 100 passed ______________________________________ % 40 20 15 10 10 5 ______________________________________
The filtrate obtained above is white and unclear, and there are a large amount of adhesion of the polymer onto the reactor wall and the agitating blades.
At the initiation of and during the polymerization reaction, the agitation should be done with a large power, and about two times or more of agitation rate than that in the present invention is required in order to effect the homogeneous mixing.
When the particles are dried for the same time as in the present invention, the molded product obtained therefrom shows undesirable silver streaks and can not be practically used.
The beads-like particles (100 parts by weight) are admixed with calcium stearate (0.3 part by weight) and Sumilizer® BHT (0.3 part by weight). After mixing well, the mixture is directly molded by an injection molding. As the result, the beads-like particles are badly bitten into the injection machine and therefore it is necessary to slow the rate of the injection molding.
In the same manner as described in Example 1, polybutadiene latex (70 parts by weight), styrene (21 parts by weight) and acrylonitrile (9 parts by weight) are polymerized in a 10 liter glass reactor. The graft polymer thus obtained (1,800 g, the solid materials: 41%) is mixed with deionized water (4,144 g), and the mixture is agitated at 300 r.p.m. To the mixture is added at one time a mixture of styrene (896 g), acrylonitrile (384 g), lauroyl peroxide (3.2 g), t-dodecylmercaptan (10 g) and tris-monylphenyl phosphite (10 g).
To the mixture is added a 2% aqueous solution of polyethylene oxide having an average molecular weight of 2 × 106 (100 g), but there can not be obtained a stable aqueous dispersion and the aqueous solution as mentioned above (200 g) should be additionally added thereto. The mixture is heated up to 75° C and polymerized for 5 hours. After the polymerization reaction, the reaction product is cooled, filtered, washed with water and dried at 70° C for 13 hours. The filtrate thus obtained is white and unclear. At the initiation of and during the polymerization reaction, the agitation power is higher than that in Examples 1 to 3 of the present invention, but it is not necessary to increase the rate of the agitation as in Reference Example 1. The time for drying of the particles obtained in this Reference Example 2 is shorter than that in Reference Example 1, but is far longer than that in Example 1 to 3. The particles of Reference Example 2 has the following distribution of particle sizes:
______________________________________ Mesh 20 40 60 80 100 100 passed ______________________________________ % 20 37 29 10 5 0 ______________________________________
The particles (100 parts by weight) are admixed with calcium stearate (0.3 part by weight) and Sumilizer® BHT (0.3 part by weight). After mixing well, the mixture is directly molded by an injection molding. As the result, the particles are badly bited into the injection machine as like as in Reference Example 1.
Various properties of the products in Example 1 to 3 and in Reference Example 1 and 2 were measured on the molded test pieces. The results are shown in the following Table 1.
Table 1
______________________________________
Reference
Example Example
1 2 3 1 2
______________________________________
Izod impact strength
(kg cm/cm.sup.2).sup.*1
37.0 38.5 38.0 21.0 25.0
(1/4", with notch, at 23° C)
Tensile strength (kg/cm.sup.2).sup.*2
356 360 355 240 270
Heat distortion
temperature (° C).sup.*3
(In annealing at 264 psi,
92.4 93.0 92.0 88.6 90.2
at 85° C, for 2 hours)
Hardness (R - Scale).sup.*4
105 105 105 89 99
Flow rate (cc/minute).sup.*5
0.108 0.102 0.105
0.038 0.076
(at 210° C, 30 kg/cm.sup.2)
______________________________________
[Remarks]:
.sup.*1 It was measured in accordance with the provision of ASTM D-256.
.sup.*2 It was measured in accordance with the provision of ASTM D-638.
.sup.*3 It was measured in accordance with the provision of ASTM D-648.
.sup.*4 It was measured in accordance with the provision of ASTM D-785-66
.sup.*5 It was measured by using Koka flow tester.
The polymer obtained in Example 1 is mixed with styrene-acrylonitrile copolymer (ηDMF = 0.62) obtained by a suspension polymerization together with an additive in the ratio as mentioned in the following Table 2. The mixture is directly molded by an injection molding to give test pieces.
The polymer obtained in Reference Example 1 is mixed with styrene-acrylonitrile copolymer used in Example 4 together with an additive in the ratio as mentioned in the following Table 2. The mixture is directly molded by an injection molding to give test pieces.
Various properties of the test samples in Example 4 and Reference Example 3 were measured. The results are shown in Table 2.
Table 2
______________________________________
Reference
Example 4 Example 3
A B C A B C
______________________________________
Polymer in Example 1
90 50 20 -- -- --
Polymer in Reference
-- -- -- 90 50 20
Example 1
Styrene-acrylonitrile
10 50 80 10 50 80
copolymer
Izod impact strength
(kg cm/cm.sup.2)
33.0 19.3 7.8 19.4 10.2 4.6
(1/4", with notch,
at 23° C)
Heat distortion
temperature (° C)
93.2 94.1 94.8 90.6 91.8 92.5
(1/4", 264 psi)
Flow rate (cc/minute)
0.120 0.18 0.22 0.06 0.14 0.19
______________________________________
[Remark]:
These properties were measured in the same manner as in Table 1.
The polymer obtained in Example 2 is mixed with styrene-acrylonitrile copolymer (ηDMF = 0.65) produced by an emulsion polymerization together with an additive in the ratio as mentioned in the following Table 3. The mixture is directly molded by an injection molding to give test pieces.
The polymer obtained in Reference Example 2 is mixed with styrene-acrylonitrile copolymer as used in Example 5 together with an additive in the ratio as mentioned in the following Table 3. The mixture is directly molded by an injection molding to give test pieces.
Various properties of the molded products in Example 5 and Reference Example 4 were measured. The results are shown in Table 3.
Table 3
______________________________________
Reference
Example 5 Example 4
A B C A B C
______________________________________
Polymer in Example 2
80 40 10 -- -- --
Polymer in Reference
-- -- -- 80 40 10
Example 2
Styrene-acrylonitrile
20 60 90 20 60 90
copolymer
Izod impact strength
(kg cm/cm.sup.2)
33.0 15.7 4.1 21.3 9.8 2.5
(1/4", with notch,
at 23° C)
Heat distortion
temperature (° C)
93.0 94.3 95.0 90.8 92.1 93.2
(1/4", 264 psi)
Flow rate (cc/minute)
0.14 0.20 0.24 0.10 0.17 0.22
______________________________________
[Remark]:
These properties were measured in the same manner as in Table 1.
Claims (8)
1. A process for producing a thermoplastic resin which comprises polymerizing an aromatic monovinyl monomer and a vinyl cyanide monomer in the presence of an aqueous elastomeric latex, and then mixing with agitation the resulting copolymer latex with an aromatic monovinyl monomer, and a vinyl cyanide monomer, together with a polyalkylene oxide and a coagulant to obtain a stable suspension phase, and further polymerizing the mixture.
2. The process according to claim 1, wherein the monomers are used in the ratio of 10 to 200 parts by weight per 100 parts by weight of the elastomer contained in the elastomeric latex in the first polymerization step.
3. The process according to claim 2, wherein the vinyl cyanide monomer is used in the ratio of 20 to 40% by weight per 80 to 60% by weight of the aromatic monovinyl monomer.
4. The process according to claim 1, wherein the monomers are used in the ratio of 30 to 2000 parts by weight per 100 parts by weight of the elastomer contained in the copolymer latex in the second polymerization step.
5. The process according to claim 4, wherein the vinyl cyanide monomer is used in the ratio of 20 to 40% by weight per 80 to 40% by weight of the aromatic monovinyl monomer.
6. The process according to claim 1, wherein the content of the elastomer in the thermoplastic resin is in the range of 5 to 70% by weight and the content of the monomers in the thermoplastic resin is in the range of 95 to 30% by weight.
7. The process according to claim 1, wherein the polyalkylene oxide has a molecular weight of 2 × 104 to 1 × 107 and is used an amount of 0.001 to 0.5 part by weight per 100 parts by weight of total weight of the copolymer latex (solid components) and the monomers.
8. The process according to claim 1, wherein the coagulant is a member selected from the group consisting of an acid having a dissociation constant of 1 × 10-5 or more at 25° C and a water-soluble salt of an organic acid having 1 to 10 carbon atoms or an inorganic acid with a monovalent, divalent or trivalent metal and is used in an amount of 0.01 to 20 parts by weight per 100 parts by weight of total weight of the copolymer latex (solid components) and the monomers.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US05/860,029 US4205019A (en) | 1975-12-26 | 1977-12-12 | Process for producing thermoplastic resin |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP51-156731 | 1975-12-26 | ||
| JP50156731A JPS5278990A (en) | 1975-12-26 | 1975-12-26 | Production of thermoplastic resins |
Related Child Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US05/860,029 Continuation US4205019A (en) | 1975-12-26 | 1977-12-12 | Process for producing thermoplastic resin |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US4112021A true US4112021A (en) | 1978-09-05 |
Family
ID=15634088
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US05/750,766 Expired - Lifetime US4112021A (en) | 1975-12-26 | 1976-12-15 | Process for producing thermoplastic resin |
Country Status (8)
| Country | Link |
|---|---|
| US (1) | US4112021A (en) |
| JP (1) | JPS5278990A (en) |
| AU (1) | AU507378B2 (en) |
| CA (1) | CA1070043A (en) |
| DE (1) | DE2658075A1 (en) |
| FR (1) | FR2336425A1 (en) |
| GB (1) | GB1533480A (en) |
| IT (1) | IT1069139B (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4336355A (en) * | 1980-10-20 | 1982-06-22 | Monsanto Company | Process for grafting large rubber particles as ABS polyblends |
| US4415708A (en) * | 1978-12-30 | 1983-11-15 | Kanegafuchi Kagaku Kogyo Kabushiki Kaisha | Three stage graft polymerization process for preparing nitrile based resins |
| US4563505A (en) * | 1982-09-22 | 1986-01-07 | Japan Synthetic Rubber Co., Ltd. | Process for producing thermoplastic graft copolymer resin containing nitrile |
Citations (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB873948A (en) | 1960-02-12 | 1961-08-02 | Shell Res Ltd | Suspension polymerisation process |
| US3370105A (en) * | 1963-05-07 | 1968-02-20 | Bell & Richardson Inc De | Process for manufacture of impact polymers |
| US3436440A (en) * | 1964-05-14 | 1969-04-01 | Hitachi Chemical Co Ltd | Method of graft-copolymerization of monomers onto diene-type polymer |
| US3703491A (en) * | 1969-12-12 | 1972-11-21 | Nitto Chem Ind Co | Abs resin composition |
| US3793403A (en) * | 1971-11-03 | 1974-02-19 | Monsanto Co | Method of producing abs type polyblend utilizing agglomerated rubber substrate of relatively monodisperse particle size and poly-blends produced thereby |
| US3804924A (en) * | 1971-11-24 | 1974-04-16 | Foster Grant Co Inc | Method of preventing build-up in a polymerization reactor |
| US3862913A (en) * | 1970-09-30 | 1975-01-28 | Bp Chem Int Ltd | Polymerisation process |
| US3957912A (en) * | 1973-12-26 | 1976-05-18 | Monsanto Company | Method for preparation of abs type resins |
| US4046839A (en) * | 1973-06-14 | 1977-09-06 | Foster Grant Co., Inc. | Compositions having high impact at low rubber levels |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE1251539C2 (en) * | 1965-01-18 | 1973-02-15 | PROCESS FOR THE PRODUCTION OF A Graft MISCLOPOLYMERIZATE |
-
1975
- 1975-12-26 JP JP50156731A patent/JPS5278990A/en active Granted
-
1976
- 1976-12-15 US US05/750,766 patent/US4112021A/en not_active Expired - Lifetime
- 1976-12-20 GB GB53118/76A patent/GB1533480A/en not_active Expired
- 1976-12-22 DE DE19762658075 patent/DE2658075A1/en active Granted
- 1976-12-23 AU AU20880/76A patent/AU507378B2/en not_active Expired
- 1976-12-24 FR FR7639094A patent/FR2336425A1/en active Granted
- 1976-12-24 IT IT70098/76A patent/IT1069139B/en active
- 1976-12-24 CA CA268,744A patent/CA1070043A/en not_active Expired
Patent Citations (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB873948A (en) | 1960-02-12 | 1961-08-02 | Shell Res Ltd | Suspension polymerisation process |
| US3370105A (en) * | 1963-05-07 | 1968-02-20 | Bell & Richardson Inc De | Process for manufacture of impact polymers |
| US3436440A (en) * | 1964-05-14 | 1969-04-01 | Hitachi Chemical Co Ltd | Method of graft-copolymerization of monomers onto diene-type polymer |
| US3703491A (en) * | 1969-12-12 | 1972-11-21 | Nitto Chem Ind Co | Abs resin composition |
| US3862913A (en) * | 1970-09-30 | 1975-01-28 | Bp Chem Int Ltd | Polymerisation process |
| US3793403A (en) * | 1971-11-03 | 1974-02-19 | Monsanto Co | Method of producing abs type polyblend utilizing agglomerated rubber substrate of relatively monodisperse particle size and poly-blends produced thereby |
| US3804924A (en) * | 1971-11-24 | 1974-04-16 | Foster Grant Co Inc | Method of preventing build-up in a polymerization reactor |
| US4046839A (en) * | 1973-06-14 | 1977-09-06 | Foster Grant Co., Inc. | Compositions having high impact at low rubber levels |
| US3957912A (en) * | 1973-12-26 | 1976-05-18 | Monsanto Company | Method for preparation of abs type resins |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4415708A (en) * | 1978-12-30 | 1983-11-15 | Kanegafuchi Kagaku Kogyo Kabushiki Kaisha | Three stage graft polymerization process for preparing nitrile based resins |
| US4336355A (en) * | 1980-10-20 | 1982-06-22 | Monsanto Company | Process for grafting large rubber particles as ABS polyblends |
| US4563505A (en) * | 1982-09-22 | 1986-01-07 | Japan Synthetic Rubber Co., Ltd. | Process for producing thermoplastic graft copolymer resin containing nitrile |
Also Published As
| Publication number | Publication date |
|---|---|
| AU2088076A (en) | 1978-06-29 |
| DE2658075C2 (en) | 1988-06-30 |
| FR2336425A1 (en) | 1977-07-22 |
| IT1069139B (en) | 1985-03-25 |
| JPS5757050B2 (en) | 1982-12-02 |
| FR2336425B1 (en) | 1982-11-19 |
| CA1070043A (en) | 1980-01-15 |
| GB1533480A (en) | 1978-11-22 |
| AU507378B2 (en) | 1980-02-14 |
| DE2658075A1 (en) | 1977-07-07 |
| JPS5278990A (en) | 1977-07-02 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| AS | Assignment |
Owner name: SUMITOMO DOW LIMITED, JAPAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:SUMITOMO NAUGATUCK CO., LTD.;REEL/FRAME:006442/0957 Effective date: 19920401 |